CAMSHAFTS IN CAMSHAFT HOUSING - R.R - INCLUDES CAMSHAFT HOUSING REPLACEMENT, IF NECESSARY

Operation 1036C10 · OVERHEAD CAMSHAFTS (2) IN CYLINDER HEAD (1)

2.2

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

1. Remove the sound insulation cover fastened to the engine by three pins.

1. Loosen the band and disconnect the engine oil vapour recovery pipe from the cylinder head cover.

2. Loosen the bands and remove the air supply hose from the air flow meter to the throttle casing.

1. Disconnect the electrical connection from the air flow meter.

2. Undo the bolts (2a) and remove the air filter cover (2b), complete with air flow meter (2c).

3. Remove the air cleaner filter element.

1. Release the fuel vapour pipe (1a) from the band (1b) on the air filter casing.

1. Disconnect the cold air intake from the air filter casing.

2. Remove the air filter casing fastened to the bodyshell by three pins.

1. Connect the tool to the bleed valve on the fuel supply pipe and discharge the fuel pressure.

Follow the safety instructions and specific recommendations.

1. Undo the connector (1a), disconnect the fuel supply pipe (1b), fuel manifold pipe side and move it to the side.

1. Disconnect the rapid connector for the fuel vapour pipe and move aside.

1. Disconnect the electrical connection from the ignition coil module.

2. Undo the bolts (2a) and remove the ignition coil module (2b).

1. Undo the nut (1a), loosen the bands and remove the engine coolant return pipe to the supply reservoir (1b).

1. Disconnect the electrical connection for the front Lambda sensor to the catalytic converter.

2. Disconnect the electrical connection for the rear Lambda sensor to the catalytic converter.

1. Unscrew the bolts securing the engine wiring bracket, timing side.

1. Unscrew the bolts securing the engine wiring bracket, cam cover side.

1. Relase the engine wiring bracket from its fastenings on the gearbox side.

2. Move the engine wiring to the side.

3. Disconnect the electrical connection for the radio interference condenser.

1. Undo the nut (1a) and disconnect the earth braid (1b) from the cam cover.

1. Undo the bolts (1a) and remove the cam cover (1b).

- Remove the spark plugs to facilitate the subsequent engine cranking operations.

1. Turn the crankshaft to move cylinder no. 4 to TDC in the combustion phase. Under these conditons, notch (1a) on the inner part of the crankshaft pulley should be aligned with the reference mark (1b) on the timing chain cover.

1. Undo the bolts (1a) and remove the timing chain upper pad (1b).

1. Unscrew and remove the automatic timing chain tensioner.

1. If no mark (1b) is present on the fixed timing chain hydraulic tensioner (1a), replace the tensioner with a new unit including a new mobile chain tensioner pad.

1. Loosen the bolts fixing the camshaft toothed drive pulleys.

Turn the hexagonal bolts on the camshafts using a fixed wrench to provide countertorque.

1. Fit the tool and check the camshaft timing setting is correct.

If necessary, turn the crankshaft slowly and gradually (in the direction of engine rotation).

1. Fully loosen the bolts fixing the camshaft toothed drive pulleys.

2. Release the amshaft toothed drive pulleys from the camshafts and leave them in place on the timing tool pins.

The chain stays fitted on the camshaft toothed pulleys.

1. Undo the bolts (1a) and remove the intake side camshaft rear cover (1b).

2. Undo the bolts and remove the intake camshaft caps.

Gradually loosen the camshaft cap bolts by half/one turn in the sequence shown in the figure. The camshaft should come away evenly from its seats.

3. Remove the intake side camshaft.

1. Undo the bolts and remove the exhaust side camshaft caps.

Gradually loosen the camshaft cap bolts by half/one turn in the sequence shown in the figure. The camshaft should come away evenly from its seats.

2. Remove the exhaust side camshaft.

Refitting

If the camshafts are replaced, also replace the rockers.

1. Replace the exhaust side camshaft in its housing.

Moisten the sliding surfaces with MoS2 lubricant paste (grey)

2. Refit the exhaust side camshaft caps.

Position the camshaft caps in accordance with the markings stamped on them and shown in the figure.

3. Tighten the exhaust side camshaft cap bolts to the specified torque in the sequence shown in the figure.

1. Replace the intake side camshaft in its housing.

Moisten the sliding surfaces with MoS2 lubricant paste (grey)

2. Refit the intake side camshaft caps.

Position the camshaft caps in accordance with the markings stamped on them and shown in the figure.

3. Tighten the intake side camshaft cap bolts to the specified torque in the sequence shown in the figure.

1. Apply silicone sealant paste (grey) to the sealing surfaces of the rear intake side camshaft bearing as shown in the figure.

2. Place the intake side camshaft rear bearing (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

3. Place the exhaust side camshaft rear bearing (3a) in its housing and secure it by tightening the bolts (3b) to the recommended torque.

1. Fit the exhaust side camshaft toothed pulley (1a) on the shaft and secure by fitting a new bolt (1b) without tightening.

Adjust the hexagonal bolt on the intake side camshaft to facilitate the fit.

2. Fit the intake side camshaft toothed pulley (2a) on the shaft and secure by fitting a new bolt (1b) without tightening.

Adjust the hexagonal bolt on the exhaust side camshaft to facilitate the fit.

- The following drawing shows the timing chain hydraulic tensioner dismantled.

Replace the o-rings.

- Before the timing chain hydraulic tensioner can be refitted, it must be preloaded as described below.

1. Place the piston in a vice with protective jaws, holding by the square end.

2. Inser the piston into the tensioner case by pressing and turning as shown in the figure until pin (2a) fits into groove (2b).

3. Press and simultaneously turn the piston until pin (3a) fits into groove (3b).

- Insert the assembled piston into the tensioner body.

1. Refit the timing chain hydraulic tensioner into its seat and tighten to the specified torque.

1. Hydraulic tensioner in operational position.

If the chain remains slack, the tensioner is not in operating position.

1. Turn the crankshaft throughi 720°, then move cylinder no. 4 to TDC in the combustion phase. Under these conditons, notch (1a) on the inner part of the crankshaft pulley should be aligned with the reference mark (1b) on the timing chain cover.

When the crankshaft is turned, the tensioner piston should follow the chain through its rotation.

- Check the timing to ensure that the tool pins align with the holes on the camshaft drive pulleys.

- Remove the tool.

If they do not align, refit the timing chain without treating the coloured links on the chain as TDC reference points.

1. Place the upper timing chain pad (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

1. Tighten the new camshaft toothed pulley bolts to the specified torque, first tightening the exhaust side pulley bolt.

Turn the hexagonal bolts on the camshafts to provide countertorque.

- Fit the spark plugs and tighten them to the recommended torque.

1. Place the cam cover (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Replace the o-rings (1c).

- Connect the earth loom to the cam cover and secure with its nut.

- Connect the electrical connection for the radio interference condenser.

- Refit the engine wiring

- Secure the engine wiring bracket, gearbox side.

- Secure the cam cover engine side wiring brackets with their bolts.

- Secure the timing side engine wiring brackets with their bolts.

- Connect the electrical connection for the rear Lambda sensor to the catalytic converter.

- Connect the electrical connection for the front Lambda sensor to the catalytic converter.

- Place the coolant return pipe to the engine coolant reservoir in position and tighten the bands and the nut.

1. Place the ignition coil module (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

2. Connect the electrical connection to the ignition coil module.

- Place the fuel vapour recovery pipe in position and connect the rapid connectors.

1. Place the fuel supply pipe (1a) in its housing, connect it and tighten the connector (1b) to the recommended torque.

- Place the air filter casing in its housing and secure it to the bodyshell using the three pins.

- Connect the cold air intake to the air filter casing.

- Fasten the fuel vapour pipe to the air filter casing using the band.

- Fit the air filter filter element in place.

- Fit the cover for the air filter, complete with air flow meter, and secure it using the bolts.

- Connect the electrical connection to the air flow meter.

- Place the air supply hose from the air flow meter to the throttle casing back in its housing and secure it using the bands.

- Connect the engine oil vapour recovery pipe to the cylinder head cover and secure it using the band.

- Place the sound insulation cover back in its housing and secure it to the engine using the three pins.

- Connect the negative battery terminal.

- Remove the vehicle from the lift.

1.8

Removing

Op. 1036C41 PHASE TRANSFORMER ON OVERHEAD CAMSHAFT (ONE) INTAKE EXHAUST ON CYLINDER HEAD - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.

Op. 1032C10 TIMING SYSTEM MOVING TENSIONER - R.R WITH TIMING BELT/CHAIN REMOVED

Op. 1032D31 PROTECTIVE TIMING INNER COVER - R.R. WITH TIMING BELT REMOVED

The operation for the inlet side camshaft is described below, the operation for the exhaust side camshaft is the same.

1. Remove the camshaft timing template fitted previously.

2. Disconnect the electrical connections for the phase transformer electromagnets.

3. Unscrew the bolts and remove the camshaft front cap.

4. Undo the bolts and remove the intake camshaft caps.

5. Remove the intake side camshaft.

- Remove the oil seals from the two camshafts.

The camshaft caps are numbered from 2 to 5, inlet side and from 6 to 9, exhaust side and the front cap which is the same for both camshafts, is number 1.

The bolts fixing the camshaft caps should be loosened in a spiral sequence starting from the caps at the ends in the following order: 5 - 2 - 4 - 3.

Refitting

- Remove the residues of sealant from the matching surfaces of the camshaft front cap - cylinder head

- Fit two new oil seals on the camshafts after having lubricated them with engine oil.

- Apply a bead of silicon sealant on the matching surfaces of the camshaft front cap.

- Place the camshaft front cap in position using the two centering bushes.

- Place the camshaft caps in their housings, following the progressive numbering indicated at the removal.

- Tighten the bolts fixing the camshaft caps to the recommended torque, following the spiral sequence from the inside towards the outside.

- Connect the electrical connections for the phase transformer electromagnets.

- Place the camshaft timing template in position.

Op. 1032D31 PROTECTIVE TIMING INNER COVER - R.R. WITH TIMING BELT REMOVED

Op. 1032C10 TIMING SYSTEM MOVING TENSIONER - R.R WITH TIMING BELT/CHAIN REMOVED

Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1036C41 PHASE TRANSFORMER ON OVERHEAD CAMSHAFT (ONE) INTAKE EXHAUST ON CYLINDER HEAD - R.R.